Subaru Legacy (2005 year). Manual — part 282

ME(H4DOTC)-71

MECHANICAL

Cylinder Block

24) Remove the service hole cover and service
hole plugs using a hexagon wrench [14 mm].

25) Rotate the crankshaft to bring #1 and #2 pis-
tons to bottom dead center position, then remove
the piston snap ring through service hole of #1 and
#2 cylinders.

26) Draw out the piston pins from #1 and #2 pistons
using ST.
ST

499097600

PISTON PIN REMOVER
ASSY (MT MODEL)

ST

499097700

PISTON PIN REMOVER
ASSY (EXCEPT FOR MT
MODEL)

NOTE:
Be careful not to confuse the original combination
of piston, piston pin and cylinder.

27) Similarly remove the piston pins from #3 and #4
pistons.
28) Remove the bolts which connect cylinder block
on the side of #2 and #4 cylinders.

29) Loosen the bolts which connect cylinder block
on the side of #1 and #3 cylinders for two or three
turns.
30) Place the cylinder block to face the #1 and #3
cylinder side upward, and remove cylinder block
connecting bolts.

ME-00140

ME-00141

ME-00142

ST

ME(H4DOTC)-72

MECHANICAL

Cylinder Block

31) Separate the cylinder block (LH) and (RH).

NOTE:
When separating the cylinder block, do not allow the connecting rod to fall and damage the cylinder block.

32) Remove the rear oil seal.
33) Remove the crankshaft together with connect-
ing rod.
34) Remove the crankshaft bearings from cylinder
block using a hammer handle.

NOTE:
Do not confuse the combination of crankshaft bear-
ings. Press the bearing at the end opposite to lock-
ing lip.
35) Draw out each piston from cylinder block using
a wooden bar or hammer handle.

NOTE:
Be careful not to confuse the original combination
of piston and cylinder.

(1)

Cylinder block

(3)

Crankshaft

(5)

Piston

(2)

Rear oil seal

(4)

Crankshaft bearing

ME-00143

(2)

(3)

(4)

(4)

(5)

(5)

(1)

(1)

ME(H4DOTC)-73

MECHANICAL

Cylinder Block

B: INSTALLATION

1) Remove oil on the mating surface of bearing and
cylinder block before installation. Apply a coat of
engine oil to crankshaft pins.
2) Position the crankshaft on the #2 and #4 cylinder
block.
3) Apply liquid gasket to the mating surface of #1
and #3 cylinder block, and position it on #2 and #4
cylinder block.

Liquid gasket:

THREE BOND 1215 (Part No. 004403007) or
equivalent

NOTE:
Do not allow liquid gasket to run over to O-ring
grooves, oil passages, bearing grooves, etc.

4) Apply a coat of engine oil to washers and bolt
threads.
5) Tighten the 10 mm cylinder block connecting
bolts on LH side (A — D) in alphabetical sequence.

Tightening torque:

10 N

⋅

m (1.0 kgf-m, 7.4 ft-lb)

(1)

Crankshaft bearing

(3)

Cylinder block

(4)

Rear oil seal

(2)

Crankshaft

ME-00144

(4)

(1)

(3)

(3)

(2)

ME-00145

ME-00840

(A)

(B)

(D)

(C)

ME(H4DOTC)-74

MECHANICAL

Cylinder Block

6) Tighten the 10 mm cylinder block connecting
bolts on RH side (E — J) in alphabetical sequence.

Tightening torque:

10 N

⋅

m (1.0 kgf-m, 7.4 ft-lb)

7) Further tighten the LH side bolts (A — D) in al-
phabetical sequence.

Tightening torque:

18 N

⋅

m (1.8 kgf-m, 13.3 ft-lb)

8) Further tighten the RH side bolts (E — J) in al-
phabetical sequence.

Tightening torque:

18 N

⋅

m (1.8 kgf-m, 13.3 ft-lb)

9) Further tighten the LH side bolts by 90

° for (A)

and (C), and to 40 N

⋅m (4.1 kgf-m, 29.5 ft-lb) for (B)

and (D), in alphabetical sequence.

10) Further tighten the RH side bolts (E — J) by 90

°

in alphabetical sequence.

11) Tighten the 8 mm and 6 mm cylinder block con-
necting bolts on LH side (A — H) in alphabetical se-
quence.

Tightening torque:

(A) — (G): 25 N

⋅

m (2.5 kgf-m, 18.4 ft-lb)

(H): 6.4 N

⋅

m (0.65 kgf-m, 4.7 ft-lb)

ME-00841

(H)

(G)

(I)

(F)

(E)

(J)

ME-00840

(A)

(B)

(D)

(C)

ME-00841

(H)

(G)

(I)

(F)

(E)

(J)

ME-00840

(A)

(B)

(D)

(C)

ME-00841

(H)

(G)

(I)

(F)

(E)

(J)

ME-00147

(B)

(C)

(D)

(E)

(F)

(G)

(H)

(A)